Trailer with rear impact guard

ABSTRACT

A trailer frame includes a rear bolster, cross-members, and corner gussets extending forwardly from ends of the rear bolster. A rear impact guard includes a bumper positioned at the rear end of the trailer and spaced below the rear bolster, pair of outboard posts, and at least one inboard post. The outboard posts extend between the bumper and the rear bolster adjacent respective opposed distal ends of the bumper, and the inboard post extends between the bumper and the rear bolster between the outboard posts. Each of the pair of outboard posts has a lower end that overlaps with a respective mounting bracket that protrudes upwardly toward the rear bolster from the bumper such that mounting holes of the outboard posts align with mounting holes of the mounting brackets. A laterally-outboard panel of each mounting bracket extends obliquely from the bumper in a direction with a laterally-outward component.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/240,237, filed Aug. 18, 2016, issued Sep. 26, 2017 as U.S. Pat. No.9,771,040, which claims priority to U.S. Provisional Patent ApplicationNo. 62/206,653, filed Aug. 18, 2015 and to U.S. Provisional PatentApplication No. 62/311,695, filed Mar. 22, 2016, and to U.S. ProvisionalPatent Application No. 62/206,661, filed Aug. 18, 2015 the entirecontents of all of which are incorporated by reference herein.

BACKGROUND

The invention relates to over-the-road trailers and rear impact guardsthereof. A conventional trailer 1000 is shown in FIG. 1, and isconfigured for over-the-road use with a truck to transport large cargovolumes. The trailer 1000 has a defined front end 1020 adapted forattachment with the truck, and a defined rear end 1040 opposite thefront end 1020. A front-rear, or lengthwise direction X is definedbetween the front and rear ends 1020, 1040, A transverse or lateraldirection Y is defined perpendicular to the lengthwise direction X. Thelengthwise and lateral directions Y are both parallel to a groundsurface along which the trailer 1000 is conveyable. The rear end 1040 inmany cases is provided with doors for accessing the cargo area definedbetween the front and rear ends 1020, 1040 (and between the sidewalls1050 and roof 1060, if so equipped). At the rear end 1040 of thetrailer, a rear impact guard 1100 is provided. The rear impact guard1100 complies with federal mandates for many common types of trailersand is designed to reduce the severity of a crash when a vehiclefollowing the trailer 1000 impacts the rear end 1040 of the trailer1000. The rear impact guard 1100 provides a lowered bumper 1110 belowthe rear sill or rear bolster 1130 at the bottom rear end of the cargoarea. However, it may be desirable to further improve safety, especiallyfor off-center impacts, while minimizing cost and weight penalties tothe trailer.

SUMMARY

In one aspect, the invention provides a trailer having a front endprovided for attachment to a truck, a rear end spaced in a longitudinaldirection from the front end to define a cargo area between the frontand rear ends, and a frame. The frame includes a rear bolster, aplurality of cross-members, and a pair of corner gussets extendingforwardly from respective distal ends of the rear bolster. The rearbolster extends transversely to the longitudinal direction below abottom rear edge of the cargo area. A rear impact guard of the trailerincludes a bumper positioned at the rear end of the trailer and spacedbelow the rear bolster, pair of outboard posts_(;) and at least oneinboard post. The pair of outboard posts extend between the bumper andthe rear bolster adjacent respective opposed distal ends of the bumper,and the at least one inboard post extends between the bumper and therear bolster at a location laterally between the pair of outboard posts.Each of the pair of outboard posts has a lower end that overlaps with arespective mounting bracket that protrudes upwardly toward the rearbolster from the bumper such that mounting holes of the outboard postsalign with mounting holes of the mounting brackets. Each mountingbracket has a laterally-outboard panel that extends obliquely from thebumper in a direction with a laterally-outward component.

In another aspect, the invention provides a trailer having a front endprovided for attachment to a truck, a rear end spaced in a longitudinaldirection from the front end to define a cargo area between the frontand rear ends, and a frame. The frame includes a rear bolster, aplurality of cross-members, and a pair of corner gussets extendingforwardly from respective distal ends of the rear bolster. The rearbolster extends transversely to the longitudinal direction below abottom rear edge of the cargo area. The cross-members extendtransversely to the longitudinal direction to define a floor structure.A rear impact guard of the trailer includes a bumper positioned at therear end of the trailer and spaced below the rear bolster, a pair ofoutboard posts, and at least one inboard post. The outboard posts extendbetween the bumper and the rear bolster adjacent respective opposeddistal ends of the bumper, and the at least one inboard post extendsbetween the bumper and the rear bolster at a location between the pairof outboard posts. Each of the pair of outboard posts is secured at anupper end thereof to a corresponding one of the pair of corner gussets.The pair of corner gussets are fortified with respective lateralreinforcement members, each of which is secured to an interior side of acorresponding one of the pair of corner gussets and each of whichextends laterally-inboard from the corresponding corner gusset.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a trailer, according to the prior art.

FIG. 2 is a perspective view of a laterally outer portion of a trailerincluding a rear impact guard according to one embodiment of theinvention.

FIG. 3 is an exploded assembly view of the laterally outer portion ofthe trailer with rear impact guard of FIG. 2.

FIG. 4 is a perspective view of the laterally outer portion of thetrailer with rear impact guard of FIG. 2, viewed from underneath thetrailer.

FIG. 5 is a perspective view of a supplementary lateral supportattachment between the rear impact guard of FIG. 2 and a trailercross-member.

FIG. 6 is a perspective view of the rear of the trailer having the rearimpact guard of FIG. 2.

FIG. 7 is a rear view of an outer post of the rear impact guard of FIG.2.

FIGS. 8 and 9 are perspective views of the outer post of FIG. 7 and amounting assembly securing an upper end of the outer post to thetrailer.

FIG. 10 is a perspective view of a bolt-on rail reinforcement assemblyassembled to a trailer frame.

FIG. 11 is a perspective view of bolt-on rail reinforcement elements ofFIG. 10 as removed from the trailer frame.

FIG. 12 is a perspective view of a bolt-on rail reinforcement assemblyaccording to another embodiment.

FIGS. 13 and 14 are perspective views of a truss-type lateral supportmember that extends between the corner gusset and the rear sill.

FIG. 15 is a perspective view of a lateral support member that extendsalong a horizontal plane between the corner gusset and the rear sill.

FIGS. 16 and 17 are perspective views of a lateral support member thatextends along the inside of the corner gusset to the rear sill.

FIG. 18 is a perspective view illustrating a lateral support member thatcombines aspects of the structure of FIGS. 13-14 with the structure ofFIGS. 16-17.

FIG. 19 is a perspective view illustrating a corner gusset havinglaterally-offset upper and lower portions so that thevertically-oriented outward-facing surface forms a flush interface withthe adjacent rail reinforcement element.

FIG. 20 is a perspective view of a portion of a rear impact guardaccording to another embodiment in which each outboard post is bolted toa mounting bracket protruding up from the distal end of the bumper.

FIG. 21 is an alternate perspective view of the rear impact guard ofFIG. 20.

FIG. 22 is an alternate perspective view of only the outboard post andthe mounting bracket of the rear impact guard of FIG. 20

FIG. 23 is a perspective view of the bumper and the mounting bracket ofthe rear impact guard of FIG. 20.

FIG. 24 is an alternate perspective view of the bumper and the mountingbracket of the rear impact guard of FIG. 20

FIG. 25 is a perspective view of the corner post of the rear impactguard of FIG. 20.

DETAILED DESCRIPTION

FIGS. 2-9 illustrate a portion of a trailer 100, which in someembodiments can be a trailer configured for over-the-road use with aroad tractor (e.g., in forming a so-called 18-wheeler) to transportlarge amounts of cargo. Aspects of the invention may not be limited tosuch types of trailers however, and it will be understood that featuresdescribed herein may also apply to many other types of trailers,including those typically having rear impact guards, and others that maynot. Similar to that of FIG. 1, the trailer 100 can include a chassishaving axles with multiple sets of wheels. The trailer 100 defines alength in a longitudinal or transport direction between its front andrear ends. The length of the trailer 100 can be 53 feet in someconstructions, although the trailer 100 can be manufactured to otherlengths greater than or less than 53 feet. Perpendicular to thelongitudinal direction, the trailer 100 defines a width and a height.The width cooperates with the length to define a plan view footprint ofthe trailer 100, while the height is measured perpendicular to thefootprint (which can be perpendicular to the ground). Subtracting forwall thicknesses, the length, the width, and the height cooperate todefine a cargo-receiving interior volume of the trailer 100. Theillustrated trailer 100 includes sidewalls, a roof, and a floor,although in other embodiments the trailer only has a floor, or only hasa floor and less than four complete sidewalls. While not shown inentirety, the illustrated trailer 100 is an enclosed trailer, but thetrailer may be a non-enclosed trailer in other constructions. In anyconstruction, the trailer 100 defines a cargo area operable to receive aload of cargo for transport. Longitudinal top rails and longitudinalbottom rails 104 extend along the length of the trailer 100 at thelateral side edges at the tops and bottoms of the lateral sidewalls,respectively. At a rear of the trailer 100 as shown in FIG. 2, anopening is provided to selectively access the cargo area for loading andunloading cargo. One or more doors may be provided to selectively closethe opening. The trailer 100 also has a load floor 106 for receiving andsupporting cargo for transport.

At the rear end of the trailer 100, two vertically-extending rear frameposts 108 are provided. The rear frame posts 108 define the lateralsides of the opening into the cargo area of the trailer 100. Along withthe longitudinal upper rails, the longitudinal bottom rails 104terminate at and are secured to the corresponding rear frame posts 108.The rear frame posts 108 can have a hollow box structure, or othersuitable construction. A rear sill or bolster 128 of the trailer frameextends along a bottom rear edge of the cargo area and has two opposinglateral distal ends secured to (e.g., welded to) the two rear frameposts 108. Below the load floor 106, a plurality of spaced-apartcross-members 112 or floor joists are provided. The cross-members 112can be spaced at intervals throughout the entire length of the trailer100, each cross-member 112 extending along a respective horizontal axisthat is transverse to the longitudinal direction of the trailer 100. Apair of longitudinally-extending slider rails 116 (one shown in FIG. 4)extend underneath the cross-members 112 in the rear section of thetrailer 100. The suspension supporting the wheels of the trailer 100 iscoupled to the slider rails 116, allowing a certain amount of movementof the suspension relative to the slider rails 116. The bottom rails104, the rear frame posts 108, the cross-members 112, and the sliderrails 116, along with additional components described below form a frameof the trailer 100.

A rear impact guard 120 is provided at the rear end of the trailer 100and is secured to the trailer frame. The rear impact guard 120 includesa plurality of elements structurally coupled to the trailer framegenerally below the rear opening of the trailer 100. The rear impactguard 120 can include a bumper 124 extending along a horizontal axis Atransversely across the rear of the trailer 100 at a height spaced belowthe cargo area. The bumper 124 can extend parallel and directly belowthe rear bolster 128. The bumper 124 may take any number ofconstructions, and may be a hollow bumper tube having a circular,rectangular, or square cross-section, among others. The illustratedbumper 124 is of tubular form, and has a modified square cross-section(when viewed along a transverse direction of the trailer 100,perpendicular to a front-rear direction of the trailer 100,) with fourequal-length sides. The cross-section of the bumper 124 can beconsistent throughout its length along an axis A. In the illustratedembodiment, the bumper 124 forms the lowest point of the rear impactguard 120 and extends across the entire width of the trailer 100, or atleast within 100 mm of the lateral extremities of the trailer 100,although other bumper dimensions are possible. Multiple posts supportthe bumper 124 relative to the trailer 100, including at least oneinboard posts 132 (e.g., a pair as shown) and a pair of outboard posts136. In some embodiments, including the illustrated embodiment, theinboard posts 132 are positioned within the central 70 percent of thewidth of the bumper 124, while the outboard posts 136 are positioned atthe distal ends of the bumper 124 (e.g., connecting to the bumper 124outside of the central 90 percent or the central 95 percent of thebumper 124).

Each of the outboard posts 136 has a similar construction, although eachis a mirror image of the other. Details of the outboard posts 136 aredescribed with respect to one of the outboard posts 136, while it willbe understood that these features also apply to the other. The outboardpost 136 can be provided with multiple attachment surfaces at its lowerend (for attachment to the bumper 124) and multiple attachment surfacesat its upper end (for attachment to the rear bolster 128, among otherportions of the trailer 100). Between the upper and lower ends of theoutboard post 136, multiple panels are provided, including at least arear panel 140 and a laterally outboard panel 142. The rear panel 140has an outer surface facing the rear of the trailer 100, and thelaterally outboard panel 142 has an outer surface facing laterallyoutward. In some embodiments, such as the illustrated embodiment, thepost 136 further includes a forward panel 144 spaced forwardly of therear panel 140. Although not required among all possible constructions,the three panels 140, 142, 144 can be integrally formed from a singlesheet of material (e.g., bent with two bends) to distinguish the threenon-planar panels 140, 142, 144. Any one or more of the panels 140, 142,144 can include one or more apertures, openings, or cutouts forstrategic weight relief to minimize the overall weight of the post 136and the rear impact guard 120. Dashed lines are used in FIG. 9 to showweight-reducing apertures, according to one exemplary layout, that canbe provided in the panel 140. FIGS. 20-22 and 25, discussed furtherbelow, also provide other examples of weight-reducing apertures.

As shown in FIG. 4, the outboard post 136 can further include a gusset145 positioned at the upper portion and secured (e.g., via welding,folding of material common to any or all of the panels 140, 142, 144,and the like) with the panels 140, 142, 144 to further strengthen thepost and provide a mounting location as discussed below. At a lower end,the outboard post 136 is provided with a mounting bracket 146 forattachment to the bumper 124. The mounting bracket 146 can be secured(e.g., via welding, folding of material common to any or all of thepanels 140, 142, 144, and the like) to one, two or all of the panels140, 142, 144. In some embodiments, the mounting bracket 146 has anon-flat shape that conforms to a portion of an outer surface of thebumper 124. The mounting bracket 146 can be a plate of uniform thickness(e.g., formed by bending a flat plate), such that the bottom ends of thepanels 140, 142, 144 also generally conform to the non-flat shape of theouter surface of the bumper 124 as shown in FIGS. 10-12. In this manner,the mounting bracket 146 can extend to and be secured to multiple sides(e.g., top and forwardly-facing side, as shown in FIG. 4 by way ofexample) of the bumper 124. In other embodiments, the mounting bracket146 is secured to only a single side of the bumper 124, such as only toa top side of the bumper 124 or to a forwardly-facing side of the bumper124. Also, in some alternative embodiments, the mounting bracket 146 isdefined in whole or in part by the bottom ends of the panels 140, 142,144, which can be shaped as described above to contact and be secured toone or more sides of the bumper 124 as also described above.

As shown in FIG. 2, the rear frame post 108 extends lower than thebottom rail 104. A corner gusset 148 of the trailer frame is secured tothe rear frame post 108, and the bottom rail 104 and/or at least one ofthe cross-members 112 to occupy the space forward of the bottom end ofthe rear frame post 108 and below the rear end of the bottom rail 104.As described below, the corner gusset 148 provides a mounting locationfor attachment of the outboard post 136 to mount the rear impact guard120 to the trailer 100.

In some embodiments, such as in the illustrated embodiment, areinforcement member 152 extends directly forward from the corner gusset148 along bottom half of the bottom rail 104, and extending below abottom edge 104A of the bottom rail 104. The illustrated reinforcementmember 152 has a triangular side profile that tapers in height towardthe forward end, although other shapes are possible while still beingattached to the other portions of the trailer frame described below.With reference again to the illustrated embodiment, in some embodimentsthe height at the rear end of the reinforcement member 152 matches thatof the corner gusset 148. However, the reinforcement member 152, or anadditional aerodynamic panel, may be provided in the profile indicatedby the dashed lines 156 in FIGS. 2 and 4. Each of the corner gusset 148and the reinforcement member 152 can have an L-shaped cross-section asseen in FIGS. 3 and 8, among others. As shown in FIGS. 4-5, a gusset 160perpendicular to both portions of the L-shaped corner gusset 148 isfixed (e.g., welded) to the corner gusset 148 to provide additionalrigidity, particularly in the lateral direction. Likewise, a gusset 162can be fixed (e.g., welded) to the cross-member 112 adjacent the cornergusset 148, and/or can be secured to the gusset 160 of the corner gusset148 via a removable fastener, such as one or more bolts. However,lateral stiffness may be supplemented in alternate ways with one or moregussets at this location or others, coupled with removable fasteners orin a permanent manner such as welding. In another example, the cornergusset can be provided with a U-shaped cross-section so that avertically-extending inboard panel is parallel to and spaced from thevertically-extending outboard panel, with a bottom panel connectedtherebetween. One or more internal gussets can be provided between thepanels that form the “U” shape of such a corner gusset. The outboardpanel can extend to a height greater than that of the inboard panel forconnection to the end or ends of at least one cross-member 112 and thebottom rail 104 of the trailer 100, while the inboard panel extends upinto contact with a bottom surface of one or more of the cross-members112.

The outboard post 136 has an upper portion that wraps around the lowerrear corner of the trailer frame to connect to the trailer framedirectly inboard of the rear frame post 108 and directly forward of therear frame post 108. With continued reference to the illustratedembodiment, a first upper edge of the outboard post 136 extends alongand is secured to a rear-facing surface of the rear bolster 128, and asecond upper edge portion of the outboard post 136 extendslongitudinally along and is secured to the corner gusset 148 along alaterally outer edge of the trailer frame. This arrangement can utilizetwo separate mounting locations, each configured for attachment to thetrailer frame with at least one removable fastener (e.g., bolts),although permanent manner of fastening (e.g., welding) are possible. Inthe illustrated embodiment, the first mounting location at the upperportion of the first panel 140 includes two laterally-spaced bolt holes.The second mounting location, at the gusset 145, includes twolongitudinally-spaced bolt holes. As shown in FIGS. 8 and 9, theoutboard post 136, in the area of the first mounting location, can forma flange that overlaps and abuts a rear-facing surface of one or both ofthe rear frame post 108 and the rear bolster 128. The outboard post 136,in the area of the second mounting location formed by the gusset 145 atthe upper end, can abut a bottom end of the rear frame post 108. Theoutboard post 136 can be releasably (e.g., bolts) or permanently (e.g.,welding) attached to the rear frame post 108 at either or both of theselocations. Additionally, the upper horizontally-lying surface of thegusset 145 may abut corresponding bottom ends of any or all of the rearbolster 128, the rear frame post 108, and the corner gusset 148. Theoutboard post 136 can be releasably (e.g., bolts) or permanently (e.g.,welding) attached to the rear bolster 128, the rear frame post 108,and/or the corner gusset 148 at any or all of these locations.

As mentioned above, the illustrated outboard post 136 has a lowerportion that at least partially wraps around the bumper 124. Forexample, the mounting bracket 146 at the lower end of the illustratedoutboard post 136 extends along a top surface of the bumper 124 andextends along a forward-facing surface of the bumper 124. Multiplemounting locations are provided by the mounting bracket 146 (e.g., holesfor receiving removable fasteners such as bolts). For example, a firstmounting hole is provided in the portion of the mounting bracket 146engaging the top of the bumper 124 and a pair of mounting holes areprovided in the portion of the mounting bracket 146 engaging theforward-facing surface of the bumper 124.

As described, the design of the outboard posts 136 allows the outboardpost 136 to be provided to the trailer frame in a bolt-on manner, andfurther allows the bumper 124 to be provided to the outboard posts 136in a bolt-on manner. As shown in the accompanying drawing views, theinboard post(s) 132 can also be provided as bolt-on components betweenthe trailer frame and the bumper 124. However, in an alternateembodiment, some or all of the connections between the posts 132, 136and the trailer frame and/or between the posts 132, 136 and the bumper124 may be of a permanent, non-removable type such as welding(“non-removable” referring to the inability to remove without damage ordestruction). For example, the lower ends of the outboard posts 136 (andoptionally, the inboard posts 132) can be welded directly to the bumper124. In such embodiments, the mounting bracket 146 may be omitted, andthe panels 140, 142, 144 may be welded directly to the bumper 124. Thegeneral shape of the lower end of the outboard post 136 can be the sameas described above to wrap around the bumper 124. If the lower end ofthe outboard post 136 is welded, but the upper end of the outboard post136 (and each inboard post 132) retains a bolt-on arrangement, the rearimpact guard 120 as a whole can be provided in a bolt-on manner to thetrailer frame. By limiting the amount of components of the rear impactguard 120 that are made integral with the trailer frame, the rear impactguard 120 and/or components thereof may be serviceable in the field withminimal time and cost, and minimal risk of damaging the trailer. Forexample, in the event of cosmetic or minimal damage to an outboard post136 or to the bumper 124, the individual component (or the rear impactguard 120 as a whole) may be removed by simply removing boltedconnections, and can then be replaced. Although bolts and nuts may beutilized throughout the rear impact guard 120 as shown and described, itwill be understood that other types of threaded fasteners may instead beutilized, as can any other type of removable fastener. In this regard,as used herein and in the appended claims the term “bolt-on” shall notbe interpreted as limiting specifically to the use of bolts.

As shown in at least FIGS. 2 and 3, the outer post 136 has an inboardedge 141, formed by the rear panel 140, and the inboard edge 141 extendsvertically. In particular, the inboard edge 141 has no lateral taper asviewed from the rear, and is extended in a vertical directionperpendicular to the bumper 124. However, as indicated at the left sideof FIG. 6, the outboard post 136 can include a tapered inboard edge 141Athat extends gradually more laterally outboard along a downward extenttoward the bumper 124. As such, the tapered inboard edge 141A can forman obtuse angle with the rear bolster 128 in rear view, while an acuteangle is formed in rear view between the inboard edge 141A and thebumper 124. This design can be incorporated on both outboard posts 136,despite only being illustrated on the left side in FIG. 6. Further, thetapered inboard edge 141A. can be combined with other aspects andembodiments of the invention disclosed herein.

Further features, usable together or alone in combination with a rearimpact guard as described above, are illustrated in FIGS. 10 to 25 anddiscussed below.

FIGS. 10 and 11 illustrate a bolt-on rail reinforcement assemblyincluding a primary reinforcement member 170 and a secondaryreinforcement member 172 that is longitudinally spaced from and alignedwith the primary reinforcement member 170. The primary reinforcementmember 170 generally replaces the reinforcement member 152 as shown inFIGS. 1-5. However, whereas the ends of the cross-members 112 abut withthe reinforcement member 152 of FIGS. 1-5, the primary reinforcementmember 170 of FIGS. 10 and 11 features recesses 174 that receive theends of the cross-members 112 so that the primary reinforcement member170 form-fits around one or more of the cross-members 112. As such, apre-standardized cross-member length (in the lateral trailer direction)can be used throughout the trailer, avoiding customized, shorter-lengthcross-members at the rear end of the trailer that is reinforced for therear impact guard. The design of the reinforcement members 170, 172.also allows installation at any given point in the assembly process, anddoes not require installation at the time of connection between thebottom rail 104 and the cross-members 112, since the reinforcementmembers 170, 172 are not sandwiched between the bottom rail 104 and theends of the cross-members 112. A triangular gusset portion 176 of theprimary reinforcement member 170 is provided to extend below the bottomrail 104, similar to the reinforcement member 152 of FIGS. 1-5. Theprimary reinforcement member 170 can be provided with mounting holes tobe secured with fasteners to the bottom rail 104 along with thecross-members 112. The optional secondary reinforcement member 172 ispositioned forward of the primary reinforcement member 170, and isprovided with a size and shape that fits between two adjacentcross-members 112. The secondary reinforcement member 172 can beentirely nested between the cross-members 112, with no gusset portionextending below the cross-members 112 or the bottom rail 104. Thesecondary reinforcement member 172 provides a reinforced connectionbetween the two adjacent cross-members 112, alongside the bottom rail104. FIG. 12 illustrates an alternate bolt-on rail reinforcementassembly in which a primary reinforcement member 170A is provided with asingle recess 174, rather than two recesses 174, and the primaryreinforcement member 170A has a shorter length that that of FIGS. 10-11.One or more secondary reinforcement members 172A, 172B can be providedforward of the primary reinforcement member 170A so that the totalreinforced length can match that of FIGS. 10-11, even with a shorterprimary reinforcement member 170A. The secondary reinforcement members172A, 172B can be of uneven lengths to accommodate the existingcross-member spacing.

FIG. 19 illustrates the primary reinforcement member 170A of FIG. 12from the exterior side of the trailer, showing how the primaryreinforcement member 170A extends between adjacent cross-members 112,without extending between the end of any cross-member 112 and the bottomrail 104, which is shown laterally-exploded in FIG. 19. Because theprimary reinforcement members 170, 170A of FIGS. 10-12 do not extendlaterally past the ends of the cross-members 112, but a portion of thecorner gusset 148 does extend laterally past the ends of thecross-members 112, a potential misalignment may occur between thelaterally outboard surfaces of the corner gusset 148 and the primaryreinforcement member 170, 170A that are exposed below the bottom edge104A of the bottom rail 104. To prevent such a misalignment, the cornergusset 148 can be constructed so that a lower portion 148L that extendsbelow the bottom rail 104 is offset laterally-inward from an upperportion 148U that is sandwiched between the cross-member ends and thebottom rail 104. The upper and lower portions 148U, 148L can be parallelwith each other and offset by an amount equal to a material thickness ofthe end plates 112A of the cross-members 112 so that the exposed outersurface of the lower portion 148L has a smooth transition to and isflush with the directly-adjacent primary reinforcement member 170, 170Aas indicated by the double arrow in FIG. 19.

FIGS. 13 and 14 illustrate a lateral reinforcement member 180 thatprovides supplemental lateral structural support for the corner gusset148 in the event of an impact to the rear impact guard of the trailer byextending in a laterally-inboard direction from an interior side of thecorner gusset 148 to which it is secured. Although only one cornergusset 148 on one side of the trailer is shown in the drawings, it willbe understood that lateral reinforcement members 180 are provided alongboth of the corner gussets 148, at opposite ends of the rear bolster128. A first or laterally-outboard end 180A of the lateral reinforcementmember 180 is secured to the corner gusset 148. A mounting hole in thefirst end 180A can also be provided for alignment with a mounting holein a tab or gusset (not shown) extending laterally-inwardly from one ofthe primary reinforcement members 170, 170A so that the lateralreinforcement member 180 can be fastened (e.g., bolted) to the primaryreinforcement member. As shown, the first end 180A can have edges thatextend along both the vertically-extending inward-facing surface 1481.and a horizontally-extending surface of a transverse flange 148B of thecorner gusset 148 (e.g., that forms a short leg of the “L” shaped cornergusset 148). The first end 180A of the lateral reinforcement member 180can be welded to the corner gusset 148 along its edges. The lateralreinforcement member 180 has a leg 182 extending laterally inward fromthe first end 180A to a second or laterally-inboard end 180B of thelateral reinforcement member 180 secured at an inwardly-spacedconnection point to the rear bolster 128. For example, the second end180B of the lateral reinforcement member 180 can be secured (e.g.,bolted or welded) to an upper return flange 128A of the rear bolster128. The lateral reinforcement member 180 can be constructed of sheetmetal that is cut into shape and bent into the form shown. Theabove-mentioned edges are formed by a sheet thickness of the materialforming the lateral reinforcement member 180. The lateral reinforcementmember 180 provides a truss effect that reinforces the corner gusset 148to inhibit the corner gusset 148 from rolling or folding over during arear impact. The lateral reinforcement member 180 allows reinforcementof the corner gusset 148 without any direct connection to any of thecross-members 112 in the trailer floor. Thus, the rear frame structureand the floor can be manufactured and assembled as separatesub-assemblies.

FIG. 15 illustrates a lateral reinforcement member 190 that providessupplemental lateral structural support for the corner gusset 148 in theevent of an impact to the rear impact guard of the trailer by extendingin a laterally-inboard direction from an interior side of the cornergusset 148 to which it is secured. Although only one corner gusset 148on one side of the trailer is shown in the drawings, it will beunderstood that lateral reinforcement members 190 are provided alongboth of the corner gussets 148, at opposite ends of the rear bolster128. A first or laterally-outboard end 190A of the lateral reinforcementmember 190 is secured to the corner gusset 148. As shown, the first end190A can lie on the horizontally-extending surface of the transverseflange 148B of the corner gusset 148. The lateral reinforcement member190 can be welded or bolted to the corner gusset 148 at the first end190A. The lateral reinforcement member 190 has a leg 192 extendinglaterally inward from the first end 190A to a second orlaterally-inboard end 190B of the lateral reinforcement member 190secured at an inwardly-spaced connection point to the rear bolster 128.For example, the second end 190B of the lateral reinforcement member 190can be secured (e.g., bolted or welded) to a lower return flange 128B ofthe rear bolster 128. Thus, the lateral reinforcement member 190 extendsin a horizontal plane, perpendicular to the vertical rear frame post108. The lateral reinforcement member 190 can be constructed of sheetmetal or plate or bar stock that is cut to length, and optionallyshaped. The lateral reinforcement member 190 provides a truss effect,providing an in-plane tensioning strap, that reinforces the cornergusset 148 to inhibit the corner gusset 148 from rolling or folding overduring a rear impact. The lateral reinforcement member 190 allowsreinforcement of the corner gusset 148 without any direct connection toany of the cross-members 112 in the trailer floor. Thus, the rear framestructure and the floor can be manufactured and assembled as separatesub-assemblies. In some constructions, the lateral reinforcement member190 may have one or more connections with the adjacent outboard post136, such as the gusset 145 thereof. In some constructions, one or bothof the ends 190A, 190B of the lateral reinforcement member 190 may haveshared connection points (e.g., bolted joints) that provide connectionsbetween the outboard post 136 and one or both of the rear bolster 128and the corner gusset 148.

FIGS. 16 and 17 illustrate a lateral reinforcement member 200 thatprovides supplemental lateral structural support for the corner gusset148 in the event of an impact to the rear impact guard of the trailer byextending in a laterally-inboard direction from an interior side of thecorner gusset 148 to which it is secured. Although only one cornergusset 148 on one side of the trailer is shown in the drawings, it willbe understood that lateral reinforcement members 200 are provided alongboth of the corner gussets 148, at opposite ends of the rear bolster128. A first or lower end 200A of the lateral reinforcement member 200is secured to the corner gusset 148. As shown, the first end 200A canhave edges that extend along both the vertically-extending inward-facingsurface 148A and a horizontally-extending surface of the transverseflange 148B. The first end 200A of the lateral reinforcement member 200can be welded to the corner gusset 148 along its edges. A mounting holein the first end 200A can also be provided for alignment with a mountinghole in a tab or gusset (not shown) extending laterally-inwardly fromone of the primary reinforcement members 170, 170A so that the lateralreinforcement member 200 can be fastened (e.g., bolted) to the primaryreinforcement member. The lateral reinforcement member 200 has a leg 202extending along the inward-facing surface 148A from the first end 200Ato a second or upper end 200B of the lateral reinforcement member 200secured (e.g., by welding) at a vertically-higher connection point tothe inward-facing surface 148, and optionally to a distal end of theupper return flange 128A of the rear bolster 128. In some constructions,an entire edge 204 of the lateral reinforcement member 200 from thefirst end 200A to the second end 200B can abut the inward facing surface148A. of the corner gusset 148, and one or more welds may secure thelateral reinforcement member 200 to the corner gusset 148 along the edge204. The lateral reinforcement member 200 can extend along a majority ofa vertical extent of the corner gusset 148. A portion of the lateralreinforcement member 200 can extend above a bottom edge 104A of thebottom rail 104, and a portion of the lateral reinforcement member 200can extend below the bottom edge 104A of the bottom rail 104. Thelateral reinforcement member 200 can be constructed of sheet metal thatis cut into shape and bent into the form shown. The above-mentionededges are formed by a sheet thickness of the material forming thelateral reinforcement member 200. The lateral reinforcement member 200serves as a transverse rib that reinforces the corner gusset 148 toinhibit the corner gusset 148 from rolling or folding over during a rearimpact. The lateral reinforcement member 200 allows reinforcement of thecorner gusset 148 without any direct connection to any of thecross-members 112 in the trailer floor. Thus, the rear frame structureand the floor can be manufactured and assembled as separatesub-assemblies.

FIG. 18 illustrates a lateral reinforcement member 210 that providessupplemental lateral structural support for the corner gusset 148 in theevent of an impact to the rear impact guard of the trailer by extendingin a laterally-inboard direction from an interior side of the cornergusset 148 to which it is secured. Although only one corner gusset 148on one side of the trailer is shown in the drawings, it will beunderstood that lateral reinforcement members 210 are provided alongboth of the corner gussets 148, at opposite ends of the rear bolster128. The lateral reinforcement member 210 incorporates features of bothFIGS. 13-14 and FIGS. 16-17. A first or lower and laterally-outboard end210A of the lateral reinforcement member 210 is secured to the cornergusset 148. As shown, the first end 210A can have edges that extendalong both the vertically-extending inward-facing surface 148A and ahorizontally-extending surface of the transverse flange 148B. The firstend 210A of the lateral reinforcement member 210 can be welded to thecorner gusset 148 along its edges. A mounting hole in the first end 210Acan also be provided for alignment with a mounting hole in a tab orgusset (not shown) extending laterally-inwardly from one of the primaryreinforcement members 170, 170A so that the lateral reinforcement member210 can be fastened (e.g., bolted) to the primary reinforcement member.The lateral reinforcement member 210 has a first leg 212 extending alongthe inward-facing surface 148A from the first end 210A to a second end210B of the lateral reinforcement member 210 secured (e.g., by welding)at a vertically-higher connection point to the inward-facing surface148, and optionally to a distal end of the upper return flange 128A ofthe rear bolster 128 (although not shown). In some constructions, anentire edge 214 of the lateral reinforcement member 210 from the firstend 210A to the second end 210B can abut the inward facing surface 148Aof the corner gusset 148, and one or more welds may secure the lateralreinforcement member 210 to the corner gusset 148 along the edge 214.The lateral reinforcement member 210 further includes a third end spacedlaterally inward from the first and second ends 210A, 210B by a secondleg 216. The third end 210C can provide a laterally-inboard connectionpoint at which the lateral reinforcement member 210 is secured (e.g., bywelding or a bolt) to an upper return flange 128A of the rear bolster128. The lateral reinforcement member 210 can be constructed of sheetmetal that is cut into shape and bent into the form shown. The lateralreinforcement member 210 provides both a rib effect and a truss effectto support the corner gusset 148.

FIGS. 20-25 illustrate another embodiment of an outboard corner post 236for a trailer rear impact guard. It will be understood that, while onecorner post 236 is illustrated, the features shown and described may beutilized at both lateral sides of the rear impact guard (e.g., where thesecond corner post is a mirror image of the corner post 236 shown). Theoutboard corner post 236 is a bolt-on post that utilizes a removable,non-permanent connection at its lower end to the bumper 124. In otherwords, the post 236 is not welded or fused to the bumper 124. Similarly,the upper end of the post 236 utilizes a removable, non-permanentconnection to the rear of the trailer frame such that the post 236 isnot welded or fused to any portion thereof. One or more inboard postsbetween the outboard posts 236 may also be provided, each extending fromthe rear bolster 128 to the bumper 124. If the inboard post(s) are alsoprovided with non-permanent connections to the trailer frame and thebumper 124, the bumper can be a serviceable item that is replaceablewithout replacing any other portion of the rear impact guard. Further,the entire rear impact guard can be manufactured and assembled as asub-assembly, separate from and attachable to the trailer frame. To theextent necessary, the rear impact guard as a whole can be a serviceableitem that is replaceable without the need for any destructive means toseparate the posts from the trailer frame. While not required in allconstructions, a rear-most panel 240 of the outboard post 236 isprovided with one or more (e.g., two) apertures that reduce the overallweight of the post 236. The illustrated layout of the apertures is onlyone exemplary embodiment, and the apertures can vary in number andlayout. In some constructions, the aperture(s) define a cumulative areathat is more than 20 percent, more than 30 percent, or even more than 40percent of a total area of the panel 240 defined by its total periphery.

Although the bumper 124 can be provided by a hollow tubular memberhaving a uniform cross-section along its axis A as shown, a stem ormounting bracket 246 can be secured to an outer surface of the bumper124 to provide mounting locations for attaching the lower end of thepost 236. Multiple mounting locations are provided by the mountingbracket 246 (e.g., holes for receiving removable fasteners such asbolts), The mounting bracket 246 can be form-fitting around multiplesurfaces of the bumper 124 and constructed to protrude therefrom. Forexample, the mounting bracket 246 can wrap around both a top side 124Aand a front side 124B of the bumper 124 as shown in FIG. 24. Themounting bracket 246 can be welded to the outer surface(s) of the tubeforming the bumper 124, thus forming a bumper assembly or weldment. Asnoted in FIGS. 22-24, the mounting bracket 246 can include multiplenon-planar panels 250, 252, 254 that respectively align with themultiple panels 240, 242, 244 of the outboard post 236 to liesurface-on-surface therewith. As shown, three panels are provided, butmore or fewer panels may be provided in other constructions. Each of thepanels 250, 252, 254 has at least one mounting hole 260, and thelaterally-outboard panel 252 includes two mounting holes 260, arrangedside-by-side. The mounting holes 260 of the mounting bracket 246correspond to an identical arrangement of mounting holes 262 on thepanels 240, 242, 244 of the post 236. In some constructions, not all ofthe panels 240, 242, 244, 250, 252, 254 include mounting holes. Forexample, in some constructions, the mounting holes 260, 262 in theforward-most panels 244, 254 are omitted.

Although the rear-most panels 240, 250 of the post 236 and the mountingbracket 246 extend vertically to define a vertical surface-to-surfaceinterface, there is at least one non-vertical surface-to-surfaceinterface defined between the post 236 and the mounting bracket 246, Inan upward direction from the bumper 124, the laterally-outboard panels242, 252 extend further laterally outboard to form an acute angle withthe bumper axis A. As such, the panels 242, 252 are oblique to the axisA. As shown in FIG. 23, the mounting holes 260 in the laterally-outboardpanel 252 define respective parallel axes B (extending centrally throughthe holes 260, perpendicular to the panel 252), both of which areoblique to the horizontal bumper axis A. As shown in FIG. 24, themounting hole 260 in the forward-most panel 254 defines an axis C(extending centrally through the hole 260, perpendicular to the panel254), which is oblique to the horizontal bumper axis A. When the post236 is assembled with the mounting bracket 246, the mounting holes 262of the post 236 align with the mounting holes 260 and assume the sameorientations as described above. The respective axes B, C define theaxes along which respective bolts (not shown) are inserted to join thepost 236 to the mounting bracket 246.

Another feature of the post 236 of FIGS. 20-25 is a supplementary orback-up plate 270 at the top end of the post 236. The back-up plate 270lies directly alongside the rearmost panel 240 in the upper areadefining the mounting location or flange 247. The flange 247 and theback-up plate 270 jointly form a pair of mounting holes 249 forconnection to the trailer frame. The back-up plate 270 reduces thetear-out stress around the bolts during an impact, inhibiting the boltsfrom tearing out of the flange 247. The added strength is providedacross the flange 247 without incurring a weight penalty that wouldaccompany the use of a thicker sheet for the entire panel 240.

It should be noted that the posts 136, 236 disclosed herein can beconstructed with one or more additional panels beyond the three-panelconstruction shown. For example, the disclosed corner posts 136, 236 ormodified variants thereof can be provided with an extended wrap-aroundflange forming a fourth panel that extends alongside the forward-mostpanel 144, 244, at an angle therewith. The fourth panel can extend in anat least partially rearward direction, and one example of such a fourthpanel 161 is shown in dashed lines in FIG. 4. Likewise is the case forthe mounting bracket 246, which can feature another panel alongside theforward-most panel 254. The fourth panel can extend

The embodiments described above and illustrated in the figures arepresented by way of example only and are not intended as a limitationupon the concepts and principles of the present invention. As such, itwill be appreciated by one having ordinary skill in the art that variouschanges in the elements and their configuration and arrangement arepossible without departing from the spirit and scope of the presentinvention as set forth in the appended claims. For example, one havingordinary skill in the art will appreciate that specific features of thenumerous embodiments disclosed may be mixed and matched in other wayswhere not specifically inhibited, even though specific illustration ofsuch embodiments may not be exhaustively covered herein.

What is claimed is:
 1. A rear impact guard for attachment to a rearframe portion of a trailer, the rear impact guard comprising: a bumperextending along an axis defining a first direction to be orientedtransversely to span laterally at a distance below the rear frameportion; a pair of outboard posts extending from respective opposeddistal ends of the bumper in a second direction so that the bumper canbe spaced below the rear frame portion by the pair of outboard posts;and at least one inboard post extending from the bumper at a locationbetween the pair of outboard posts, wherein each of the pair of outboardposts has a lower end that overlaps with a respective mounting bracketthat protrudes upwardly from the bumper such that mounting holes of theoutboard posts align with mounting holes of the mounting brackets, andwherein each mounting bracket has a laterally-outboard panel thatextends obliquely from the bumper in a direction with alaterally-outward component.
 2. The rear impact guard of claim 1,wherein each of the mounting brackets is welded to the bumper.
 3. Therear impact guard of claim 1, wherein each mounting bracket includes aforward panel, a rearward panel, and a laterally-outward panelconnecting the forward and rearward panels, and each mounting bracket isopen in a laterally-inward direction.
 4. The rear impact guard of claim1, wherein each mounting bracket includes a forward panel, a rearwardpanel, and a laterally-outward panel connecting the forward and rearwardpanels, and wherein each of the forward, rearward, and laterally-outwardpanels includes at least one mounting hole.
 5. The rear impact guard ofclaim 1, wherein the bumper has a hollow rectangular construction in across-section perpendicular to the axis.
 6. The rear impact guard ofclaim 1, wherein each of the mounting brackets wraps around both a frontside and a top side of the bumper.
 7. The rear impact guard of claim 1,wherein each of the pair of outboard posts includes a plurality ofpanels all having first ends extending from the mounting bracket on thebumper, and wherein a top gusset extends parallel to the axis betweenthe plurality of panels at opposite second ends thereof to provide anupper surface for abutment with the rear frame portion.
 4. The rearimpact guard of claim 1, wherein an upper portion of each of theoutboard posts includes apertures for establishing non-permanent,removable connections to the rear frame portion.
 9. The rear impactguard of claim 8, wherein the apertures of the upper portions of each ofthe outboard posts include at least one aperture oriented to receive afastener along a first perpendicular direction with respect to the axisdefined by the bumper, and at least one aperture oriented to receive afastener along a second perpendicular direction with respect to the axisdefined by the bumper.
 10. The rear impact guard of claim 8, wherein theapertures of the upper portions of each of the outboard posts includetwo apertures oriented to receive respective fasteners parallel to afirst perpendicular direction with respect to the axis defined by thebumper, and two apertures oriented to receive respective fastenersparallel to a second perpendicular direction with respect to the axisdefined by the bumper.
 11. A trailer comprising: a front end providedfor attachment to a truck; a rear end spaced in a longitudinal directionfrom the front end to define a cargo area between the front and rearends: a frame including a pair of laterally spaced vertical corner postsat the rear end, a rear bolster extending transversely to thelongitudinal direction below a bottom rear edge of the cargo area,between the pair of vertical corner posts, and a pair of corner gussetsextending forwardly from respective bottom portions of the pair ofvertical corner posts; and a rear impact guard including a bumperpositioned at the rear end of the trailer and spaced below the rearbolster, a pair of outboard posts, each having a lower end secured to adistal end of the bumper and an upper end secured to a laterallyoutboard portion of the frame, and at least one inboard post extendingbetween the bumper and the rear bolster at a location between the pairof outboard posts, wherein each of the pair of outboard posts includes aplurality of panels extending between the upper and lower ends, and atop gusset extending between and interconnecting the plurality ofpanels, the top gusset defining a top surface supporting a bottom ofeach of: the rear bolster, the respective one of the pair of verticalcorner posts, and the respective one of the pair of corner gussets. 12.The trailer of claim 11, wherein the plurality of panels of each of thepair of outboard posts include three panels interconnected by the topgusset.
 13. The trailer of claim 11, wherein each of the pair ofoutboard posts is secured to the frame of the trailer solely withnon-permanent, removable connections.
 14. The trailer of claim 11,wherein one of the plurality of panels of each of the pair of outboardposts is a rear panel provided with at least one aperture oriented toreceive a fastener parallel to the longitudinal direction for securingto the rear bolster, and wherein the top gusset of each of the pair ofoutboard posts is provided with at least one aperture oriented toreceive a fastener in a vertical direction parallel to the pair ofvertical corner posts for securing to the respective one of the pair ofcorner gussets.
 15. The trailer of claim 11, wherein the pair of cornergussets are fortified with respective lateral reinforcement members,each of which is secured to an interior side of a corresponding one ofthe pair of corner gussets and each of which extends laterally-inboardfrom the corresponding corner gusset.
 16. The trailer of claim 15,wherein the top gusset of each of the pair of outboard posts extends tospan underneath a position at which the respective lateral reinforcementmember is joined with the respective corner gusset.
 17. The trailer ofclaim 15, wherein each of the lateral reinforcement members has a legextending laterally inward from the respective corner gusset to aninwardly-spaced connection point at which the lateral reinforcementmember is secured to the rear bolster, and wherein each of the lateralreinforcement members has an additional leg elongated to extend along aninward-facing surface of the respective corner gusset.
 18. The trailerof claim 15, wherein the lateral reinforcement members are secured,respectively, to inward-facing surfaces of the pair of corner gussets bywelding.
 19. The trailer of claim 18, wherein each of the lateralreinforcement members has an edge abutting and extending along theinward-facing surface of the respective corner gusset.
 20. The trailerof claim 18, wherein each of the lateral reinforcement members has a legextending laterally inward from the inward-facing surface of therespective corner gusset to an inwardly-spaced connection point at whichthe lateral reinforcement member is secured to the rear bolster.